Cleaning pad and method of obtaining a clean surface thereon

ABSTRACT

A sponge and a scouring pad in which an outer surface layer can be peeled away to expose a clean surface when the outer surface of the sponge or scouring pad becomes soiled. A method of obtaining a clean surface on a sponge or scouring pad is also disclosed, wherein a predetermined thickness of the material of the sponge or pad is grasped and peeled away to expose a clean surface.

This application claims the benefit of prior U.S. Provisional PatentApplications Ser. No. 60/488,539, filed Jul. 18, 2003, and Ser. No.60/569,660, filed May 7, 2004.

TECHNICAL FIELD

This invention relates to cleaning tools, and more particularly, to arenewable cleaning pad, namely, a sponge or scouring pad in which soiledlayers can be removed to expose a clean surface, thereby prolonging theuseful life of the cleaning pad.

Background Art

Sponges and scouring pads are used in households and different types ofindustries for many diverse tasks. For example, sponges are commonlyused for cleaning various surfaces, such as kitchen counter tops, wallsurfaces, and floors, or for washing dishes, or washing automobiles, andthe like. Sponges also are used for applying or removing cosmetics, orto apply paint or stain to a surface, and for many other purposes.Scouring pads, being more abrasive, typically are used for cleaningsurfaces that are soiled with more difficult to remove contaminants,such as, for example, barbecue grills, cooking utensils, and the like,or for removing paint from a surface, or for other similar tasks.Inevitably, with continued use the outer surface of the sponge orscouring pad becomes contaminated or soiled to the point that it is nolonger satisfactory for use. It generally is only the external surfaceof the sponge or scouring pad that is dirty, and the internal body ofthe sponge or scouring pad remains relatively clean. However, sinceconventional sponges and scouring pads are manufactured as integral,one-piece blocks or bodies of material, when the outer surface becomesunsatisfactory for use, it is necessary to discard the entire sponge orscouring pad and replace it with a new one. This means that every time asponge or scouring pad is thrown away, a very large portion of thesponge or scouring pad material is unnecessarily wasted. Moreover,conventional sponges as typically used for household cleaning chores,for example, and scouring pads, in particular, are relatively thin anduncomfortable to use for some tasks.

U.S. Pat. No. 6,405,403 and published pending US applications2002/0083964, 2002/0118993 and 2004/0031119, all disclose cleaningimplements in which discrete, individual, thin sheets of cleaningmaterial are laminated together in layers so that when the outer sheetbecomes soiled or unsuitable for use, it can be peeled off the stack anddiscarded, exposing a clean sheet for use. The cleaning material isdescribed as a non-woven or a paper towel-like bibulous material, or abibulous sponge-like or woven material. There is no suggestion of asponge or scouring pad body that is made in one integral unitary piece,but in which an outer layer can be removed to expose a clean surface.

Accordingly, there is need for a sponge and/or scouring pad in which anouter surface layer can be removed to expose a clean surface forcontinued use of the sponge and/or scouring pad.

DISCLOSURE OF THE INVENTION

The present invention comprises a cleaning pad in which an outer surfacelayer can be removed to expose a clean surface, thus prolonging theuseful life of the cleaning pad and minimizing waste. As used herein,“cleaning pad” is intended to encompass both sponges and scouring pads,and specifically, an integrally formed one-piece sponge or scouring pad.

The cleaning pad of the invention (sponge or scouring pad) can becombined with known accessories, such as dish washing handles, mops,soap dispensers, and the like.

A scouring pad according to the present invention may be manufactured ofconventional materials using substantially conventional manufacturingtechniques. The difference between the prior art and the scouring pad ofthe invention is that an outer surface layer of the scouring pad of theinvention can be removed to expose a clean surface, thereby prolongingthe useful life of the scouring pad. Any one or a combination of severalways achieves this.

In a first embodiment, as shown in FIG. 1, the scouring pad is madeconventionally, except that it preferably has a greater thickness than aconventional scouring pad. For instance, the scouring pad may have athickness of about three inches, as compared with conventional scouringpads that typically have a thickness no greater than about one inch.When the exterior surface of the pad becomes soiled so that it is nolonger suitable for use, the material or fibers of the pad at one edgeare grasped and separated at a suitable depth from the soiled surface,e.g., about one-half inch, and pulled back away from the body of thepad, forming a layer that is carefully peeled away from the body of thepad, thereby exposing a clean surface. The relatively thick pad permitsa layer to be removed that has sufficient thickness to avoid tearing ofthe layer. That is, by peeling off a sufficiently thick layer the fibersof the pad will separate relatively uniformly along a plane parallel toone of the surfaces of the pad.

Depending upon the material and construction of the pad, it may bepossible in some instances to separate the fibers uniformly along aplane to enable a thinner layer to be peeled away, as shown in FIG. 2.

A second embodiment of the invention is shown in FIGS. 3 and 4, whereinthe fibers or material of the pad are connected only at spaced locationslying in a plane extending transversely through the body of the pad.This facilitates separation of soiled layers of the pad along the planeswhere the material of the pad is connected only at a number oflocations. The disconnected areas can be formed by any suitable means,such as by making a series of cuts or slits laterally through the bodyof the pad from one or more edges of the pad, parallel to one of theouter surfaces, or by using a suitable media during manufacture of thepad to prevent connection of the fibers at predetermined locations. Thiscreates weak areas of uncut material near the lateral sides that can beeasily torn apart.

A third embodiment is shown in FIGS. 5 and 6, wherein one or moreapertured separation sheets are embedded in the pad during itsmanufacture to prevent adherence or connection of the fibers of the padat predetermined locations lying in a plane parallel to one of the padsurfaces, thereby facilitating separation of a layer of the pad toexpose a clean surface.

A fourth embodiment of the invention is shown in FIGS. 7 and 8. In thisembodiment, a scouring pad is adhered at one side to a sponge. Thescouring pad preferably is constructed so that layers of the pad can beremoved to expose a clean surface. This can be achieved as in theprevious embodiments, or the scouring pad can be made in thin layers andadhesively laminated together.

A fifth embodiment is shown in FIGS. 9 and 10. This embodiment comprisesa sponge that has a plurality of cuts or slits formed laterally throughthe body of the sponge, forming weakened areas lying in a plane parallelto one of the surfaces of the pad to permit thin layers of the sponge tobe peeled off to expose a clean surface.

Alternatively, inserts can be placed inside the mold cavity duringmanufacture of the sponge, arranged in such a way that the material ofthe sponge is kept separated at predetermined locations during theinjection process, thus forming planes of weakness in the sponge bodyalong which a layer of sponge can be separated from the main body.

A variation of the scouring pad is shown in FIG. 11, wherein the pad hasthe shape of a truncated pyramid. This provides a larger base than top,whereby the pad can be used to clean in corners, or against adjacentvertical surfaces, without the sides of the pad coming into contact withthe adjacent surface. Also, this configuration avoids bumping of theuser's fingers against adjacent surfaces when the pad is being usedclose to adjacent vertical surfaces and the like.

A similar configuration of the sponge is shown in FIG. 12. The truncatedpyramid shaped sponge has the same advantages as the pad discussedabove.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing, as well as other objects and advantages of the invention,will become apparent from the following detailed description when takenin conjunction with the accompanying drawings, wherein like referencecharacters designate like parts throughout the several views, andwherein:

FIG. 1 is a top perspective view of a scouring pad according to a firstembodiment of the invention.

FIG. 2 is a top perspective view of a variation of the FIG. 1embodiment.

FIG. 3 is a top perspective view of a scouring pad according to a secondembodiment of the invention.

FIG. 4 is a top perspective view of the pad of FIG. 3, showing a layerof the pad being peeled away to expose a clean surface.

FIG. 5 is a top perspective view of a third embodiment of scouring padaccording to the invention, showing use of a separation sheet to defineareas of weakness lying in a plane to facilitate separation of a layerof the pad along the plane.

FIG. 6 is a top perspective view of a variation of the embodiment shownin FIG. 5.

FIG. 7 is a top perspective view of a fourth embodiment of theinvention, wherein a scouring pad having areas of weakness to facilitatepeeling off layers of the pad is laminated at one side to a sponge.

FIG. 8 is a top perspective view of the embodiment of FIG. 7, showing alayer of the scouring pad being peeled away.

FIG. 9 is a top perspective view of a fifth embodiment of the invention,wherein the cleaning pad is a sponge.

FIG. 10 is a top perspective view of the sponge of FIG. 9, showing alayer of the sponge being peeled away.

FIG. 11 is a top perspective view of a modified scouring pad, whereinthe pad has the shape of a truncated pyramid.

FIG. 12 is a top perspective view of a modified sponge, wherein thesponge has the shape of a truncated pyramid.

BEST MODES FOR CARRYING OUT THE INVENTION

The scouring pad 10 shown in the embodiment of FIG. 1 essentiallycomprises a bundle of tangled fibers compressed together into a porousmass, and has a thickness “t” sufficient to permit one or more layers 11of substantially uniform thickness to be separated from the body of thepad by breaking or separating the material of the pad, i.e., the fibers,along a plane parallel to a surface S of the pad. Thus, when the surfaceS becomes soiled and is no longer suitable for use, the material of thepad can be grasped at one edge of the pad and pulled away from the padbody, breaking apart the fibers along a plane substantially parallel tothe soiled surface, so that a layer of substantially uniform thicknesscan be pulled away to expose a clean surface. To insure separation of alayer having substantially uniform thickness, the plane of separationshould be spaced approximately one-half inch from the soiled surface,although in some instances it may be possible to separate a relativelythin layer 12 as shown in FIG. 2, depending upon the composition andstructure of the pad 10′.

In the second embodiment shown in FIGS. 3 and 4, a plurality of cuts orslits 13 are made in the scouring pad 14, extending laterally across theinterior of the pad body from one or more edges thereof. The cuts formareas of weakness lying in spaced parallel planes along which successivelayers 15 of the pad can be removed to expose a clean surface whendesired. The areas of weakness may be formed during manufacture of thepad, or post manufacture, and may be made by any suitable means,including cutting blades, laser, mold inserts, etc. The provision ofweakened areas facilitates removal of a layer from the pad, and enablesseparation from the pad of layers that are thinner than in the firstembodiment.

FIG. 5 depicts a third embodiment, wherein one or more spaced apartparallel separation sheets 20 are embedded in the scouring pad 21 duringits manufacture. The sheets 20 separate the material of the pad inpredetermined locations between adjacent layers, forming planes ofweakness along which a layer can be separated from the pad. The sheetshave openings 22 formed therein through which the material of adjacentlayers is connected or joined to form a one-piece, unitary body. Tofacilitate grasping of an edge portion to initiate separation of alayer, the sheets can extend in selected locations through the edge ofthe pad, whereby portions of the material between adjacent layers at theedge of the pad are not attached and can be easily separated or spreadapart to initiate tearing.

A variation of the third embodiment is shown in FIG. 6, wherein theholes or openings 22′ through the separation sheet 20′ are differentlyshaped and extend through at least one edge of the pad body so that thematerial of the pad is joined in those areas 23 at the edge of the pad.

A fourth embodiment is shown in FIG. 7, wherein a scouring pad 25 islaminated with a sponge 26. The sponge is conventional, but the scouringpad is manufactured so that a layer or layers 27 of the pad can beremoved when the outer surface S becomes soiled. To this end, aplurality of cuts or slits 13 can be made in the scouring pad, extendinglaterally across the interior of the pad from one or more edges thereofto define areas of weakness along which a layer of the pad can beremoved, or the scouring pad can comprise a tangled compressed bundle offibers, as in embodiment 1, that will break when pulled, thus allowingseparation of the layer.

Alternatively, and as shown in FIG. 8, the pad 28 can be formed inseparate layers 29 that are then laminated together by use of anadhesive 30, or a heat seal, or other suitable attaching means. In thisregard, the attachment between adjacent layers must be such as to permita layer to be readily separated from the pad when desired, but strongenough to hold the layers together during use.

A fifth embodiment of the invention is shown in FIGS. 9 and 10, whereinthe cleaning pad comprises a sponge 40. The sponge is manufactured ofconventional materials using essentially conventional manufacturingmethods, but either during manufacture or post manufacture, one or morecuts or slits 41 are formed laterally through the sponge body from oneor more edges thereof, defining areas of weakness lying in one or morespaced apart parallel planes that are parallel to a surface S of thesponge. Layers 42 of the sponge may be separated from the sponge bodyalong these planes to expose a clean surface when the outer surfacebecomes soiled.

A variation of the FIGS. 1 and 2 embodiment is shown at 50 in FIG. 11.In this figure, the scouring pad 50 has the shape of a truncatedpyramid. For example, the base 51 could measure five inches on a side,the top 52 could measure three inches on a side, and the height “h” ofthe pad could measure three inches. Other dimensions could be used toobtain the same result. For instance, the base and top could berectangular rather than square as shown in FIG. 11. Layers 53 of thisscouring pad could be peeled away to expose a clean surface, representedin broken lines, just as in the previous embodiments.

A variation of the sponge is shown at 60 in FIG. 12, wherein the spongeis shaped as a truncated pyramid. For example, the base 61 could measurefive inches on a side, the top 62 could measure three inches on a side,and the height “h” of the sponge could measure three inches. Otherdimensions could be used to obtain the same result. For instance, thebase and top could be rectangular rather than square as shown in FIG.12. Cuts or areas of separation 63 may be formed in this sponge tofacilitate separation of layers 64, just as in the previous embodiments.

Although particular embodiments of the invention are illustrated anddescribed in detail herein, it is to be understood that various changesand modifications may be made to the invention without departing fromthe spirit and intent of the invention as defined by the scope of theappended claims.

1. A cleaning pad in which an outer, soiled surface of the pad can beremoved to expose a clean surface, said cleaning pad comprising aone-piece, integrally formed, unitary body formed of a material capableof being separated along planes parallel to the soiled surface so that alayer of the material containing the soiled surface can be peeled awayfrom the pad to expose the clean surface.
 2. A cleaning pad as claimedin claim 1, wherein: said material comprises a sponge material.
 3. Acleaning pad as claimed in claim 1, wherein: said material comprises acompressed bundle of tangled fibers.
 4. A cleaning pad as claimed inclaim 1, wherein the pad has the shape of a truncated pyramid.
 5. Ascouring pad in which an outer, soiled surface layer of the pad can beremoved to expose a clean surface, comprising: a one-piece, integrallyformed, unitary scouring pad body formed of a material adapted forscouring a surface, said material being interrupted in predeterminedlocations to define a weakened area lying in a plane parallel to thesoiled surface and along which the material may be separated in a layerto expose a clean surface.
 6. A scouring pad as claimed in claim 5,wherein: the interruptions in the material are formed by one or morecuts made in the pad, extending laterally across the interior of the padfrom at least one edge thereof.
 7. A scouring pad as claimed in claim 5,wherein: the interruptions in the material are formed by one or moreseparation sheets embedded in the material of the pad, said sheetshaving at least one opening through which the material is connectedbetween adjacent layers.
 8. A cleaning pad, comprising: a scouring padlaminated to a sponge, said scouring pad formed in separable layers thatmay be peeled off the pad to expose a clean surface when an outersurface of the scouring pad becomes soiled.
 9. A sponge in which anouter, soiled surface layer of the sponge can be removed to expose aclean surface, comprising: a one-piece, integrally formed, unitarysponge body formed of a sponge-like material, said material beinginterrupted in predetermined locations to define a weakened area lyingin a plane parallel to the soiled surface and along which the materialmay be separated in a layer to expose a clean surface.
 10. A sponge asclaimed in claim 9, wherein: the interruptions in the material areformed by one or more cuts made in the sponge, extending laterallyacross the interior of the sponge from at least one edge thereof.
 11. Asponge as claimed in claim 9, wherein the sponge has the shape of atruncated pyramid.
 12. A method of exposing a clean surface on ascouring pad when a surface thereof becomes soiled, comprising the stepsof: providing a unitary, integrally formed, one-piece scouring padhaving a first predetermined thickness and made of a material capable ofbeing separated; grasping a second predetermined thickness of thematerial at an edge portion of the pad and peeling the material back toremove a layer of the material to expose said clean surface.
 13. Amethod of exposing a clean surface on a sponge when a surface thereofbecomes soiled, comprising the steps of: providing a unitary, integrallyformed, one-piece sponge having a first predetermined thickness and madeof a material capable of being separated; grasping a secondpredetermined thickness of the material at an edge portion of the spongeand peeling the material back to remove a layer of the material toexpose said clean surface.
 14. A method as claimed in claim 13,including the steps of: forming cuts or slits in the body of the spongeto define weakened areas along which the layer of material is removed.